odd sized front rotor required

CryptoKnight

CryptoKnight
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I have been fabricating a custom springer. Now that it's all assembled, I find that the shoulder bolts are barely, but actually, rubbing on the rotor. This means I have to mount the front wheel off-center (not!), find a smaller rotor, or change my springer design. Changing the springer design is non-trivial, because it would mean refabricating the rockers and change the dimensions of the springer itself, a huge pain.

I'm hoping for smaller rotor. The wheel is this one from KC Int., basically a 2003 Dyna/2003 XL wheel. What I need is a front brake rotor with HD bolt pattern for the Dyna that is about 11" to 11.2". 11.25" might work ok, it's tight.

I know this is wacky. I've been looking and not finding. Short of getting a piece of stainless and taking it to the lathe (and hardening with nitrogen, argh!!!) where from here? Any ideas?
 
If this is your current springer, I can see why things are close:

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Original Harley springers had narrowed fork ends, with the thicker pivot bosses in the rockers.
Gets a little more room.

Only bandaids I can think of, for now, are:
- Like you said, offset the wheel hub a bit. Then adjust spokes to recenter the rim.
- Use a large press, and deform/deflect the rotor's hub outward, dishing it like a belleville spring, moving the rotor inboard...
 
Yup, that's the one. Good options. I did find a 10" rotor but with older narrow hole for pre-2000 hub. So, that's also an option, to punch that out to stock.
 
So, the ultimate answer was rotors from 74 FL, which are 10" with 2.375" center. Drag Specialties sold them in matching set for front with the above 10", and rear with 11.5" and 2" center. 5-hole pattern hasn't changed, fortunately. Pics in the Big Red Devil album, and in XS650 Chop Off thread.
 
The stars must be aligned. Good save, Krypto...

Thanks! Lucky break was an obscure parts book that included the 74 Shovelhead part number as the fitment on a solid 10" rotor. Once I got that part number, it broke the code and options came tumbling out... but that was something like 50 hours of searching into the problem.

Going with low-profile titanium shoulder bolts was the other option, but that was nearly $800 for 4 bolts... with no guarantees the bolts were of sufficient strength.
 
Would you be able to run a drum on the front. Might be easier to rebuild the wheel on a different hub than redo the springer
 
If I can't find a caliper, that might be the path home. That or rear brake only. A friend in the motorcycle biz has offered to help me find an old banana caliper and see if we can shave them.
 
The guys at GS Resources have had some luck using Kawasaki twin pot calipers on bikes with front wheel clearance issues.
 
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